Cartridge assembly comprising a blocking element

ABSTRACT

A cartridge assembly for an aerosol-generating system is provided, including a mouthpiece housing, a blocking element, and a cartridge. The mouthpiece housing has an upstream end, a downstream end, and a mouthpiece cavity. The blocking element is secured within the mouthpiece cavity. The cartridge is positioned at the upstream end of the mouthpiece housing, the cartridge including an upstream end, a downstream end, a first compartment, and a second compartment. The downstream end of the cartridge abuts an upstream end of the blocking element. The cartridge is rotatable with respect to the blocking element from a first position to a second position. In the first position, the blocking element obstructs first and second air outlets of the first and second compartments respectively. In the second position, the first and second air outlets are in fluid communication with the mouthpiece cavity.

The present invention relates to a cartridge assembly for use in anaerosol-generating system and an aerosol-generating system comprisingthe cartridge assembly. The invention finds particular application as acartridge assembly comprising a nicotine source and an acid source forthe generation of an aerosol comprising nicotine salt particles.

Devices for delivering nicotine to a user and comprising a nicotinesource and a volatile delivery enhancing compound source are known. Forexample, WO 2008/121610 A1 discloses devices in which nicotine and avolatile acid, such as pyruvic acid, are reacted with one another in thegas phase to form an aerosol of nicotine salt particles that is inhaledby the user.

In WO 2008/121610 A1 the nicotine source and volatile delivery enhancingcompound source may be housed in compartments that are sealed byremovable or frangible barriers prior to initial use of theaerosol-generating system.

However, the inclusion of multiple removable or frangible barriers maydisadvantageously increase the cost and complexity of manufacturing suchaerosol-generating systems. Consequently, it would be desirable toprovide a cartridge assembly for use in an aerosol-generating system inwhich one or more volatile compounds may be retained during storage andwhich minimises the need for removable or frangible barriers.

According to a first aspect of the present invention there is provided acartridge assembly for use in an aerosol-generating system, thecartridge assembly comprising a mouthpiece housing, a blocking elementand a cartridge. The mouthpiece housing has an upstream end and adownstream end, the mouthpiece housing defining a mouthpiece cavityextending between the upstream end of the mouthpiece housing and thedownstream end of the mouthpiece housing. The blocking element issecured within the mouthpiece cavity and comprises an upstream end and adownstream end. The cartridge is positioned at the upstream end of themouthpiece housing, the cartridge comprising an upstream end and adownstream end. The cartridge also comprises a first compartment havinga first air inlet at the upstream end of the cartridge and a first airoutlet at the downstream end of the cartridge. The cartridge alsocomprises a second compartment having a second air inlet at the upstreamend of the cartridge and a second air outlet at the downstream end ofthe cartridge. The downstream end of the cartridge abuts the upstreamend of the blocking element. The cartridge is rotatable with respect tothe blocking element from a first position to a second position. Theblocking element is shaped so that the upstream end of the blockingelement obstructs the first air outlet and the second air outlet whenthe cartridge is in the first position, and the first air outlet and thesecond air outlet are both in fluid communication with the mouthpiececavity when the cartridge is in the second position.

As used herein with reference to the invention, the term “air inlet” isused to describe one or more apertures through which air may be drawninto a component or portion of a component of the cartridge assembly.

As used herein with reference to the invention, the term “air outlet” isused to describe one or more apertures through which air may be drawnout of a component or portion of a component of the cartridge assembly.

As used herein with reference to the invention, by “obstructed” it ismeant that an air inlet or an air outlet is blocked such that airflowthrough the air inlet or the air outlet is substantially prevented.

The cartridge assembly according to the present invention comprises ablocking element configured to obstruct the first and second air outletsof the cartridge when the cartridge is in the first position.Advantageously, this can eliminate the need to provide a removable orfrangible seal at the downstream end of the cartridge.

The cartridge assembly according to the present invention comprises acartridge configured to rotate with respect to the blocking element froma first position in which the blocking element obstructs the first andsecond air outlets to a second position in which the first and secondair outlets are in fluid communication with the mouthpiece cavity.Advantageously, this can simplify use of the cartridge assembly byallowing a user to uncover the first and second air outlets without theneed to remove a seal or break a seal at the downstream end of thecartridge.

The cartridge assembly may be configured so that the cartridge isrotatable with respect to the blocking element between the firstposition and the second position. That is, the cartridge may beconfigured for rotation from the first position to the second positionand configured for rotation from the second position to the firstposition. This may allow a user to rotate the cartridge from the secondposition to the first position to re-obstruct the first and second airoutlets. Advantageously, this may reduce the loss of one or morevolatile compounds that may be stored within at least one of the firstcompartment and the second compartment between separate uses of thecartridge.

One of the blocking element and the cartridge may comprise an aperture,wherein the other of the blocking element and the cartridge comprises ashaft, and wherein at least a portion of the shaft is positioned withinthe aperture. Advantageously, the combination of the shaft and theaperture facilitates rotation of the cartridge with respect to theblocking element. Advantageously, the combination of the shaft and theaperture may be simple to manufacture and assemble.

Preferably, the aperture forms a plain bearing.

The aperture may extend through the blocking element between theupstream end of the blocking element and the downstream end of theblocking element, wherein the shaft extends from the downstream end ofthe cartridge. Advantageously, this arrangement may facilitateembodiments in which a length of the shaft is longer than a length ofthe aperture. In particular, the mouthpiece cavity may accommodate anyportion of the shaft which extends beyond the downstream end of theblocking element.

Preferably, the shaft comprises a journal portion positioned within theaperture and a retaining portion at an end of the journal portion,wherein the retaining portion is positioned outside of the aperture andhas a diameter that is larger than a diameter of the aperture.Advantageously, the retaining portion retains the journal portion of theshaft within the aperture and prevents separation of the cartridge fromthe blocking element and the mouthpiece housing.

The blocking element may comprise a first part defining a first side ofthe aperture and a second part defining a second side of the aperture,wherein the first and second parts are formed separately and joinedtogether to form the blocking element. Advantageously, forming theblocking element from two separate parts may facilitate assembly of thecartridge assembly. For example, the journal portion of the shaft may bepositioned within at least one of the first side of the aperture andsecond side of the aperture before the first and second parts are joinedtogether to form the blocking element.

The first and second parts may be joined together by at least one of aninterference fit, an adhesive, and a weld, such as an ultrasonic weld.

The retaining portion may comprise a tapered portion. Advantageously,providing the retaining portion with a tapered portion may facilitateinsertion of the retaining portion through the aperture during assemblyof the cartridge assembly, particularly in embodiments in which theblocking element is formed as a unitary element. In such embodiments,preferably the maximum diameter of the tapered portion is sufficientlysmall so that elastic deformation of the material forming the blockingelement can accommodate the retaining portion when it is pushed throughthe aperture during assembly of the cartridge assembly.

Preferably, the cross-sectional size of the tapered portion increases inthe upstream direction along the length of the tapered portion from adownstream end of the tapered portion. Advantageously, this mayfacilitate insertion of the retaining portion into the aperture duringassembly of the cartridge assembly. Preferably, an upstream end of thetapered portion has a diameter that is larger than a diameter of theaperture. Preferably, the downstream end of the tapered portion has adiameter that is smaller than a diameter of the aperture. The taperedportion may comprise a cross-sectional size that varies linearly alongthe length of the tapered portion. For example, the tapered portion mayhave a conical shape. The tapered portion may comprise a cross-sectionalsize that varies non-linearly along the length of the tapered portion.For example, the tapered portion may have a rounded shaped.

Preferably, the shaft comprises a step change in diameter between theupstream end of the tapered portion and the downstream end of thejournal portion, wherein the downstream end of the journal portion has adiameter that is smaller than the diameter of the upstream end of thetapered portion. Advantageously, a step change in diameter may preventthe tapered portion being pulled back through the aperture after thecartridge assembly has been assembled.

The cartridge may comprise a guiding pin extending from the downstreamend of the cartridge, wherein the guiding pin abuts a first portion ofthe blocking element when the cartridge is in the first position, andwherein the guiding pin abuts a second portion of the blocking elementwhen the cartridge is in the second position. Advantageously, theguiding pin may facilitate precise rotation of the cartridge into thesecond position by a user. In embodiments in which the cartridge canalso be rotated from the second position into the first position, theguiding pin may facilitate precise rotation of the cartridge into thefirst position by a user. Preferably, the guiding pin is spaced apartfrom an axis of rotation of the cartridge with respect to the blockingelement so that the guiding pin follows an arcuate path when thecartridge is rotated from the first position to the second position.

Preferably, the blocking element comprises a guide opening extendingthrough the blocking element between the upstream end of the blockingelement and the downstream end of the blocking element, wherein theguiding pin is received within the guide opening. Preferably, theguiding pin abuts a first side of the guide opening when the cartridgeis in the first position. Preferably, the guiding pin abuts a secondside of the guide opening when the cartridge is in the second position.

The blocking element may comprise a first recess formed in the firstside of the guide opening, wherein the guiding pin is received withinfirst recess by an interference fit when the cartridge is in the firstposition. Advantageously, the interference fit may cause the guiding pinto snap into the first recess when the cartridge is moved into the firstposition from the second position. This may provide a user with atactile confirmation that the cartridge has been successfully rotatedinto the first position. The blocking element may comprise a firstdetent extending into the guide opening to provide the interference fitbetween the first recess and the guiding pin.

The blocking element may comprise a second recess formed in the secondside of the guide opening, wherein the guiding pin is received withinsecond recess by an interference fit when the cartridge is in the secondposition. Advantageously, the interference fit may cause the guiding pinto snap into the second recess when the cartridge is moved into thesecond position from the first position. This may provide a user with atactile confirmation that the cartridge has been successfully rotatedinto the second position. The blocking element may comprise a seconddetent extending into the guide opening to provide the interference fitbetween the second recess and the guiding pin.

The blocking element may comprise only the first recess, only the secondrecess, or both the first recess and the second recess. In embodimentsin which the cartridge assembly is configured so that the cartridge maybe rotated only from the first position to the second position,preferably the interference fit between the guiding pin and the secondrecess is substantially irreversible. That is, the force required toremove the guiding pin from the second recess may be at least double theforce required to insert the guiding pin into the second recess. Theinterference fit may be such that the guiding pin cannot be rotated outof the second recess without breaking the guiding pin.

The cartridge may comprise a cartridge housing positioned at theupstream end of the mouthpiece housing and rotatable with respect to theblocking element from the first position to the second position, and acartridge body secured within the cartridge housing, the cartridge bodydefining the first compartment and the second compartment.Advantageously, forming the cartridge from a cartridge housing and acartridge body may simplify the manufacture of the cartridge.

Preferably, the cartridge housing comprises a downstream end wall.

Preferably, the first and second air outlets extend through thedownstream end wall.

In embodiments in which the cartridge comprises a shaft, preferably theshaft extends downstream from the downstream end wall. Preferably, theshaft is formed integrally with the downstream end wall.

In embodiments in which the cartridge comprises a guiding pin,preferably the guiding pin extends downstream from the downstream endwall. Preferably, the guiding pin is formed integrally with thedownstream end wall.

Preferably, the cartridge housing defines a cartridge housing cavity inwhich the cartridge body is received. Preferably, the cartridge housingdefines a cartridge housing opening at an upstream end of the cartridgehousing. Advantageously, the cartridge body may be inserted into thecartridge housing cavity through the cartridge housing opening.

The cartridge body and the cartridge housing may be shaped to limit thenumber of rotational orientations of the cartridge body with respect tothe cartridge housing in which the cartridge body may be inserted intothe cartridge housing. Preferably, the cartridge body and the cartridgehousing are shaped so that the cartridge body may be inserted into thecartridge housing in only a single rotational orientation. Inembodiments in which the first and second air outlets extend through adownstream wall of the cartridge housing, preferably the rotationalorientation is such that, when the cartridge body is received within thecartridge housing, a downstream end of the first compartment overliesthe first air aperture and a downstream end of the second compartmentoverlies the second air aperture.

The cartridge body may be retained within the cartridge housing by atleast one of an interference fit, an adhesive, and a weld, such as anultrasonic weld. Preferably, the cartridge body is retained within thecartridge housing by an interference fit. Advantageously, aninterference fit simplifies the manufacture and assembly of thecartridge.

The cartridge body may be formed as a single part.

The cartridge body comprise a first part and a second part joined to thefirst part to form the cartridge body. Advantageously, forming thecartridge body from first and second parts may facilitate the insertionof a material into at least one of the first compartment and the secondcompartment during assembly of the cartridge assembly.

The first part of the cartridge body may define a first side of thefirst compartment and a first side of the second compartment. The secondpart of the cartridge body may define a second side of the firstcompartment and a second side of the second compartment. Any materialsto be positioned within the first compartment may be positioned withinthe first side of the first compartment or the second side of the firstcompartment before the first and second parts are joined together toform the cartridge body. Any materials to be positioned within thesecond compartment may be positioned within the first side of the secondcompartment or the second side of the second compartment before thefirst and second parts are joined together to form the cartridge body.

The first and second parts of the cartridge body may be joined togetherby at least one of an interference fit, an adhesive, and a weld, such asan ultrasonic weld. Preferably, the first and second parts of thecartridge body are joined together by an interference fit.Advantageously, an interference fit simplifies the manufacture andassembly of the cartridge body.

Preferably, the cartridge body comprises an upstream end wall, whereinthe first and second air inlets are defined by the upstream end wall.

The blocking element may be spaced apart from the downstream end of themouthpiece housing, wherein a portion of the mouthpiece cavity betweenthe downstream end of the blocking element and the downstream end of themouthpiece housing forms a mixing chamber. In embodiments describedherein in which the first compartment comprises a source of a firstvolatile compound and the second compartment comprises a source of asecond volatile compound, advantageously the mixing chamber mayfacilitate mixing of vaporised first and second volatile compounds fromthe first and second compartments before the mixture is delivered to auser.

The mouthpiece housing may comprises a ventilation air inlet positionedbetween the blocking element and the downstream end of the mouthpiecehousing, the ventilation air inlet extending through the mouthpiecehousing and providing fluid communication between the exterior of themouthpiece housing and the mixing chamber.

The mouthpiece housing may comprise a downstream wall portion extendingacross the downstream end of the mouthpiece cavity, the mouthpiecehousing comprising a mouthpiece housing air outlet extending through thedownstream wall portion. In use, airflow through the cartridge assemblyexits the cartridge assembly through the mouthpiece housing air outletfor delivery to a user.

The blocking element may be secured within the mouthpiece housing by atleast one of an interference fit, an adhesive, and a weld, such as anultrasonic weld. Preferably, the blocking element is secured within themouthpiece housing by an interference fit. Advantageously, aninterference fit simplifies the manufacture and assembly of thecartridge assembly.

The blocking element may comprise a first airflow aperture configured tooverlie the first air outlet when the cartridge is in the secondposition and a second airflow aperture configured to overlie the secondair outlet when the cartridge is in the second position.

Preferably, the blocking element has a circular shape. The first airflowaperture and the second airflow aperture may each have an arcuate shape.

In embodiments in which the blocking element comprises a guide openingconfigured to interact with a guiding pin on the cartridge, the firstairflow aperture or the second airflow aperture may form the guideopening.

The first airflow aperture and the second airflow aperture may bediametrically opposed. Advantageously, providing diametrically opposedfirst and second airflow apertures may facilitate positioning of thefirst and second compartments on opposite sides of the cartridge.Advantageously, this may facilitate a balanced distribution of weightwithin the cartridge, which may facilitate handling of the cartridge andthe cartridge assembly during manufacturing processes.

The first airflow aperture and the second airflow aperture may eachextend along a quarter-circular arc length. In embodiments in which thefirst airflow aperture and the second airflow aperture are diametricallyopposed and each extend along a quarter-circular arc length, the firstposition and the second position may be offset from each other by anangular rotation of the cartridge through 90 degrees with respect to theblocking element.

In embodiments in which the downstream end of the blocking element has acircular shape, the downstream end of the blocking element defines acircumferential direction and a radial direction. Preferably, each ofthe first and second airflow apertures has a maximum length in thecircumferential direction of at least about 3.5 millimetres, morepreferably at least about 4 millimetres. Preferably, each of the firstand second airflow apertures has a maximum length in the circumferentialdirection of less than about 5.5 millimetres, more preferably less thanabout 5 millimetres.

Preferably, each of the first and second airflow apertures has a maximumwidth in the radial direction of at least about 2 millimetres, morepreferably at least about 2.5 millimetres.

Preferably, each of the first and second airflow apertures has a maximumwidth in the radial direction of less than about 4 millimetres, morepreferably less than about 3.5 millimetres.

The blocking element may have a diameter of at least about 6millimetres, preferably at least about 6.5 millimetres. The blockingelement may have a diameter of less than about 9 millimetres, preferablyless than about 8.5 millimetres.

Preferably, each of the first and second airflow apertures has a maximumflow area of at least about 3.5 square millimetres, more preferably atleast about 4 square millimetres, more preferably at least about 4.5square millimetres. Preferably, each of the first and second airflowapertures has a maximum flow area of less than about 6 squaremillimetres, more preferably less than about 5.5 square millimetres,more preferably less than about 5 square millimetres.

The ratio of the maximum flow area of each of the first and secondairflow apertures to the surface area of the downstream end of theblocking element is preferably at least about 0.06, more preferably atleast about 0.08, more preferably at least about 0.1. The ratio of themaximum flow area of each of the first and second airflow apertures tothe surface area of the downstream end of the blocking element ispreferably less than about 0.2, more preferably less than about 0.16,more preferably less than about 0.14.

The blocking element may comprise a first blocking portion positionedbetween a first end of the first airflow aperture and a second end ofthe second airflow aperture. The blocking element may comprise a secondblocking portion positioned between a second end of the first airflowaperture and a first end of the second airflow aperture. The firstblocking portion is configured to obstruct the first air outlet when thecartridge is in the first position and the second blocking portion isconfigured to obstruct the second air outlet when the cartridge is inthe first position.

The cartridge assembly may further comprise a seal extending across theupstream end of the cartridge. Preferably, the seal is secured to thecartridge about a periphery of the seal to seal the first air inlet andthe second air inlet. In embodiments in which the cartridge comprises acartridge housing and a cartridge body, the seal may be secured to atleast one of the cartridge housing and the cartridge body. The seal maybe secured to the cartridge by at least one of an adhesive and a weld,such as an ultrasonic weld. The seal is preferably formed from a sheetmaterial. The sheet material may comprise at least one of a polymericfilm and a metallic foil.

The seal may be a frangible seal configured to be pierced by a piercingelement on an aerosol-generating device.

The seal may be a removable seal configured to be removed by a userbefore using the cartridge assembly. The removable seal may comprise apull tab to facilitate removal of the seal by a user.

The first air outlet may comprise a single first air outlet aperture.The first air outlet may comprise a plurality of first air outletapertures, each first air outlet aperture in fluid communication withthe downstream end of the first compartment. Each first air outletaperture may have a minimum cross-sectional area, the minimumcross-sectional area being the flow area of the first air outletaperture. The total flow area of the first air outlet is the sum of theflow areas of the one or more first air outlet apertures.

The second air outlet may comprise a single second air outlet aperture.The second air outlet may comprise a plurality of second air outletapertures, each second air outlet aperture in fluid communication withthe downstream end of the second compartment. Each second air outletaperture may have a minimum cross-sectional area, the minimumcross-sectional area being the flow area of the second air outletaperture. The total flow area of the second air outlet is the sum of theflow areas of the one or more second air outlet apertures.

The total flow area of the first air outlet may be the same as the totalflow area of the second air outlet. The total flow area of the first airoutlet may be different to the total flow area of the second air outlet.Different total flow areas may be selected to provide different flowrates of air through each of the first compartment and the secondcompartment. In embodiments in which the cartridge comprises a source ofa first volatile compound positioned within the first compartment and asource of a second volatile compound in the second compartment,providing different flow rates through the first and second compartmentsmay account for a difference between a vapour pressure of the firstvolatile compound and a vapour pressure of the second volatile compoundat the same temperature. In embodiments in which the first and secondvolatile compounds undergo a chemical reaction with each other to form areaction product for delivery to a user, providing different flow ratesthrough the first and second compartments may provide a desired reactionstoichiometry between the first and second volatile compounds downstreamof the cartridge.

The optional and preferred features described herein with respect to thefirst and second air outlets may be applied equally to the first andsecond air inlets. That is, each of the first and second air inlets maycomprise one or more air inlet apertures. The total flow area of thefirst air inlet may be the same as the total flow area of the second airinlet. The total flow area of the first air inlet may be different tothe total flow area of the second air inlet.

The cartridge assembly may comprise a first indicium on the mouthpiecehousing and a second indicium on the cartridge. Preferably, the indiciaare configured such that the position of the first indicium with respectto the second indicium provides a visual indication to a user of therotational orientation of the cartridge with respect to the mouthpiecehousing. Advantageously, providing a visual indication of a rotationalorientation of the cartridge allows a user to determine whether thefirst and second air outlets are obstructed by the blocking element orunobstructed and in fluid communication with the mouthpiece cavity.

The cartridge assembly may comprise a nicotine source positioned withinthe first compartment. The cartridge assembly may comprise an acidsource positioned within the second compartment.

As used herein with reference to the invention, the term “nicotine”, isused to describe nicotine, nicotine base or a nicotine salt.

The nicotine source may comprise a first carrier material impregnatedwith between about 1 milligram and about 50 milligrams of nicotine. Thenicotine source may comprise a first carrier material impregnated withbetween about 1 milligram and about 40 milligrams of nicotine.Preferably, the nicotine source comprises a first carrier materialimpregnated with between about 3 milligrams and about 30 milligrams ofnicotine. More preferably, the nicotine source comprises a first carriermaterial impregnated with between about 6 milligrams and about 20milligrams of nicotine. Most preferably, the nicotine source comprises afirst carrier material impregnated with between about 8 milligrams andabout 18 milligrams of nicotine.

In embodiments in which the first carrier material is impregnated withnicotine base or a nicotine salt, the amounts of nicotine recited hereinare the amount of nicotine base or amount of ionised nicotine,respectively.

The first carrier material may be impregnated with liquid nicotine or asolution of nicotine in an aqueous or non-aqueous solvent.

The first carrier material may be impregnated with natural nicotine orsynthetic nicotine.

The acid source may comprise an organic acid or an inorganic acid.

Preferably, the acid source comprises an organic acid, more preferably acarboxylic acid, most preferably an alpha-keto or 2-oxo acid or lacticacid.

Advantageously, the acid source comprises an acid selected from thegroup consisting of 3-methyl-2-oxopentanoic acid, pyruvic acid,2-oxopentanoic acid, 4-methyl-2-oxopentanoic acid,3-methyl-2-oxobutanoic acid, 2-oxooctanoic acid, lactic acid andcombinations thereof. Advantageously, the acid source comprises pyruvicacid or lactic acid. More advantageously, the acid source compriseslactic acid.

Advantageously, the acid source comprises a second carrier materialimpregnated with acid.

The first carrier material and the second carrier material may be thesame or different.

Advantageously, the first carrier material and the second carriermaterial have a density of between about 0.1 grams/cubic centimetre andabout 0.3 grams/cubic centimetre.

Advantageously, the first carrier material and the second carriermaterial have a porosity of between about 15 percent and about 55percent.

The first carrier material and the second carrier material may compriseone or more of glass, cellulose, ceramic, stainless steel, aluminium,polyethylene (PE), polypropylene, polyethylene terephthalate (PET),poly(cyclohexanedimethylene terephthalate) (PCT), polybutyleneterephthalate (PBT), polytetrafluoroethylene (PTFE), expandedpolytetrafluoroethylene (ePTFE), and BAREX®.

The first carrier material acts as a reservoir for the nicotine.

Advantageously, the first carrier material is chemically inert withrespect to nicotine.

The first carrier material may have any suitable shape and size. Forexample, the first carrier material may be in the form of a sheet orplug.

Advantageously, the shape and size of the first carrier material issimilar to the shape and size of the first compartment of the cartridge.

The shape, size, density and porosity of the first carrier material maybe chosen to allow the first carrier material to be impregnated with adesired amount of nicotine.

Advantageously, the first compartment of the cartridge may furthercomprise a flavourant. Suitable flavourants include, but are not limitedto, menthol.

Advantageously, the first carrier material may be impregnated withbetween about 3 milligrams and about 12 milligrams of flavourant.

The second carrier material acts as a reservoir for the acid.

Advantageously, the second carrier material is chemically inert withrespect to the acid.

The second carrier material may have any suitable shape and size. Forexample, the second carrier material may be in the form of a sheet orplug.

Advantageously, the shape and size of the second carrier material issimilar to the shape and size of the second compartment of thecartridge.

The shape, size, density and porosity of the second carrier material maybe chosen to allow the second carrier material to be impregnated with adesired amount of acid.

Advantageously, acid source is a lactic acid source comprising a secondcarrier material impregnated with between about 2 milligrams and about60 milligrams of lactic acid.

Preferably, the lactic acid source comprises a second carrier materialimpregnated with between about 5 milligrams and about 50 milligrams oflactic acid. More preferably, the lactic acid source comprises a secondcarrier material impregnated with between about 8 milligrams and about40 milligrams of lactic acid. Most preferably, the lactic acid sourcecomprises a second carrier material impregnated with between about 10milligrams and about 30 milligrams of lactic acid.

The shape and dimensions of the first compartment of the cartridge maybe chosen to allow a desired amount of nicotine to be housed in thecartridge.

The shape and dimensions of the second compartment of the cartridge maybe chosen to allow a desired amount of acid to be housed in thecartridge.

The ratio of nicotine and acid required to achieve an appropriatereaction stoichiometry may be controlled and balanced through variationof the volume of the first compartment relative to the volume of thesecond compartment.

In embodiments in which the cartridge assembly comprises a nicotinesource positioned within the first compartment and an acid sourcepositioned within the second compartment, nicotine vapour released fromthe nicotine source in the first compartment of the cartridge and acidvapour released from the acid source in the second compartment of thecartridge may react with one another in the gas phase in the mouthpiececavity to form an aerosol of nicotine salt particles.

The first compartment of the cartridge may be coated with one or morenicotine-resistant materials and the second compartment of the cartridgemay be coated with one or more acid-resistant materials.

Examples of suitable nicotine-resistant materials and acid-resistantmaterials include, but are not limited to, polyethylene (PE),polypropylene (PP), polystyrene (PS), fluorinated ethylene propylene(FEP), polytetrafluoroethylene (PTFE), epoxy resins, polyurethaneresins, vinyl resins and combinations thereof.

Use of one or more nicotine-resistant materials to one or both of formthe cartridge and coat the interior of the first compartment of thecartridge may advantageously enhance the shelf life of the cartridgeassembly.

Use of one or more acid-resistant materials to one or both of form thecartridge and coat the interior of the second compartment of thecartridge may advantageously enhance the shelf life of the cartridgeassembly.

The cartridge assembly may comprise one or more aerosol-modifying agentspositioned within the mouthpiece cavity. For example, mouthpiece cavitymay contain one or more sorbents, one or more flavourants, one or morechemesthetic agents or a combination thereof.

The cartridge may comprise a third compartment for receiving a heatingelement of an aerosol-generating device. Preferably, the thirdcompartment is positioned between the first compartment and the secondcompartment. That is, the first compartment and the second compartmentare disposed on either side of the third compartment. Preferably, thethird compartment comprises a compartment opening at the upstream end ofthe cartridge. In use, a heating element of an aerosol-generating deviceis received within the third compartment to heat the first compartmentand the second compartment.

The cartridge may comprise a susceptor for inductively heating the firstcompartment and the second compartment. In such embodiments, thesusceptor is advantageously located between the first compartment andthe second compartment. That is, the first compartment and the secondcompartment are disposed on either side of the susceptor.

In use, heating the first compartment and the second compartment of thecartridge to a temperature above ambient temperature advantageouslyenables control of the vapour concentrations of volatile compoundsstored within the first and second compartments. For example, inembodiments in which the cartridge assembly comprises a nicotine sourcepositioned within the first compartment and an acid source positionedwithin the second compartment, heating the first and second compartmentsenables the vapour pressure of nicotine in the first compartment and thevapour pressure of acid in the second compartment to be controlled andbalanced proportionally to yield an efficient reaction stoichiometrybetween the nicotine and the acid. Advantageously, this may improve theefficiency of the formation of nicotine salt particles and theconsistency of delivery to a user. Advantageously, it may also reducethe delivery of unreacted nicotine and unreacted acid to a user.

Each of the cartridge, the blocking element, and the mouthpiece housingmay be formed from any suitable material or combination of materials.Suitable materials include, but are not limited to, aluminium, polyetherether ketone (PEEK), polyimides, such as Kapton®, polyethyleneterephthalate (PET), polyethylene (PE), high-density polyethylene(HDPE), polypropylene (PP), polystyrene (PS), fluorinated ethylenepropylene (FEP), polytetrafluoroethylene (PTFE), polyoxymethylene (POM),epoxy resins, polyurethane resins, vinyl resins, liquid crystal polymers(LCP) and modified LCPs, such as LCPs with graphite or glass fibres.

The cartridge, the blocking element, and the mouthpiece housing may beformed from the same or different materials. Preferably, the mouthpiecehousing is formed from at least one of polyethylene (PE) andpolypropylene (PP). Preferably, the blocking element is formed frompolyethylene (PE). In embodiments in which the cartridge comprises acartridge housing, preferably the cartridge housing is formed frompolypropylene (PP). In embodiments in which the cartridge comprises acartridge body, preferably the cartridge is formed from at least one ofpolyether ether ketone (PEEK) and liquid crystal polymers (LCP).

The cartridge assembly may simulate the shape and dimensions of acombustible smoking article, such as a cigarette, a cigar, or acigarillo. Advantageously, in such embodiments the cartridge assemblymay simulate the shape and dimensions of a cigarette.

The cartridge assembly may have a length of between about 20 millimetresand about 60 millimetres, preferably between about 30 and about 50millimetres, more preferably between about 35 millimetres and about 45millimetres.

The cartridge assembly may have a diameter of between about 5millimetres and about 10 millimetres, preferably between about 6millimetres and about 9 millimetres, more preferably between about 7millimetres and about 8 millimetres.

According to a second aspect of the present invention there is providedan aerosol-generating system comprising an aerosol-generating device anda cartridge assembly according to the first aspect of the presentinvention, in accordance with any of the embodiments described herein.The aerosol-generating device comprises a device cavity configured toreceive an upstream end of the cartridge assembly and a heater forheating the first compartment and the second compartment of thecartridge of the cartridge assembly.

In those embodiments in which the cartridge comprises a thirdcompartment for receiving a heating element, the heater of theaerosol-generating device advantageously comprises a heating elementpositioned within the device cavity and configured to be received withinthe third compartment of the cartridge when the upstream end of thecartridge assembly is received within the device cavity. The heatingelement may be a resistive heating element. In use, the heating elementis received within the third compartment and heats the first compartmentand the second compartment.

In those embodiments in which the cartridge comprises a susceptorpositioned between the first compartment and the second compartment, theheater of the aerosol-generating device advantageously comprises aninductive heater surrounding at least a portion of the device cavity. Inuse, the inductive heater inductively heats the susceptor, which heatsthe first compartment and the second compartment.

The aerosol-generating system may be configured so that, in use, theheater heats the first compartment and the second compartment of thecartridge to a temperature of below about 250 degrees Celsius.Preferably, the aerosol-generating system is configured so that theheater heats the first compartment and the second compartment of thecartridge to a temperature of between about 80 degrees Celsius and about150 degrees Celsius.

Preferably, the aerosol-generating system is configured so that, in use,the heater heats the first compartment and the second compartment of thecartridge to substantially the same temperature.

The aerosol-generating device may further comprise a power supply forsupplying power to the heater and a controller configured to control asupply of power from the power supply to the heater.

The aerosol-generating device may comprise one or more temperaturesensors configured to sense the temperature of at least one of theheater, the first compartment, and the second compartment. In suchembodiments, the controller may be configured to control a supply ofpower to the heater based on a sensed temperature.

For the avoidance of doubt, features described above in relation to oneaspect of the invention may also be applicable to other aspects of theinvention. In particular, features described above in relation to thecartridge assembly of the invention may also relate, where appropriate,to the aerosol-generating systems of the invention, and vice versa.

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings, in which:

FIG. 1 shows a perspective view of a cartridge assembly according to anembodiment of the present invention;

FIG. 2 shows an exploded perspective view of the cartridge assembly ofFIG. 1;

FIG. 3 shows perspective views of the cartridge housing and thecartridge body of FIG. 2;

FIG. 4 shows a view of the upstream end of the cartridge body of FIG. 2;

FIG. 5 shows an exploded view of the downstream end of the cartridgebody of FIG. 2;

FIG. 6 shows a perspective view of the cartridge housing of FIG. 2; and

FIG. 7 shows a view of the downstream end of the blocking element ofFIG. 2.

FIG. 1 shows a cartridge assembly 10 according to an embodiment of thepresent invention. The cartridge assembly comprises a mouthpiece housing12 and a cartridge 14 configured for rotation with respect to themouthpiece housing 12. The mouthpiece housing 12 comprises a downstreamend wall 16 extending across a downstream end 18 of the mouthpiecehousing 12. The mouthpiece housing 12 defines a mouthpiece cavity 20 andcomprises a mouthpiece housing air outlet 22 extending through thedownstream end wall 16 and in fluid communication with the mouthpiececavity 20. A plurality of indicia 24 on the outside of the mouthpiecehousing 12 and the cartridge 14 indicate the rotational orientation ofthe cartridge 14 with respect to the mouthpiece housing 12.

FIG. 2 shows an exploded perspective view of the cartridge assembly 10of FIG. 1. As shown in FIG. 2, the cartridge assembly 10 furthercomprises a blocking element 26 that is secured by an interference fitin the downstream end 28 of the mouthpiece housing 12. The mouthpiececavity 20 extends between a downstream end 30 of the blocking element 26and the downstream end wall 16 of the mouthpiece housing 12.

The cartridge 14 comprises a cartridge housing 32 and a cartridge body34 that is secured within the cartridge housing 32 by an interferencefit. A removable seal 36 is secured to the upstream end of the cartridge14, the removable seal 36 configured to be removed by a user prior tousing the cartridge assembly 10.

FIG. 3 shows the cartridge housing 32 and the cartridge body 34 infurther detail. The cartridge housing 32 comprises a downstream end 38and an upstream end 40, the cartridge housing 32 defining a cavity 42for receiving the cartridge body 34. The upstream end 40 of thecartridge housing 32 is open for insertion of the cartridge body 34 intothe cavity 42 during manufacture of the cartridge 14. The cartridge body34 comprises a first compartment 44, a second compartment 46 and a thirdcompartment 48 positioned between the first and second compartments 44,46. The first and second compartments 44, 46 are open at theirdownstream ends 50, 52 at the downstream end 54 of the cartridge body34. The cartridge housing 32 and the cartridge body 34 comprise matingportions 56, 58 so that the cartridge body 34 can be inserted into thecartridge housing 32 in only a single orientation. This ensures correctalignment between the downstream ends of the first and secondcompartments 44, 46 and first and second air outlets provided on thedownstream end 38 of the cartridge housing 32, as will be furtherdescribed with reference to FIG. 6.

FIG. 4 shows the upstream end 60 of the cartridge body 34, whichcomprises a first air inlet 62 comprising a plurality of first air inletapertures in fluid communication with the first compartment 44 and asecond air inlet 64 comprising a plurality of second air inlet aperturesin fluid communication with the second compartment 46. The thirdcompartment 48 is open at the upstream end 60 of the cartridge body 34to receive a heater of an aerosol-generating device for heating thefirst and second compartments 44, 46. In an alternative embodiment thecartridge body 34 may comprise a susceptor positioned within the thirdcompartment 48 for use with an aerosol-generating device comprising aninductive heater.

FIG. 5 shows an exploded view of the downstream end 54 of the cartridgebody 34. The cartridge body 34 comprises a first part 66 and a secondpart 68 that are secured together by an interference fit to form thecartridge body 34. The first part 66 defines the third compartment 48, afirst side 70 of the first compartment 44, and a first side 72 of thesecond compartment 46. The second part 68 defines a second side 74 ofthe first compartment 44, a second side 76 of the second compartment 46,the first air inlet 62 and the second air inlet 64. During manufactureand assembly of the cartridge body 34, a nicotine source 78 is insertedinto the second side 74 of the first compartment 44 and an acid source80 is inserted into the second side 76 of the second compartment 46,prior to the first and second parts 66, 68 being secured together.

As shown in FIG. 6, the cartridge housing 32 comprises a downstream endwall 82 extending across a downstream end 38 of the cartridge housing32. The cartridge housing 32 further comprises a shaft 84 extending fromthe downstream end wall 82, the shaft 84 comprising a journal portion 86and a retaining portion 88. The retaining portion 88 has a rounded shapeand has a maximum diameter that is larger than the diameter of thejournal portion 86. The cartridge housing 32 further comprises a guidingpin 90 extending from the downstream end wall 82, a first air outlet 92and a second air outlet 94. When the cartridge body 34 is receivedwithin the cartridge housing 32 the first air outlet 92 is in fluidcommunication with the downstream end 50 of the first compartment 44 andthe second air outlet 94 is in fluid communication with the downstreamend 52 of the second compartment 46.

The first air outlet 92 comprise a different number of first air outletapertures compared to the number of second air outlet apertures formingthe second air outlet 94. The different number of air outlet aperturesprovides different flow rates of air through the first and secondcompartments 44, 46 during use of the cartridge assembly 10 to accountfor the different vapour pressures of the nicotine source 78 and theacid source 80. Therefore, the different flow rates of air through thefirst and second compartments 44, 46 maintains a required reactionstoichiometry between nicotine vapour and acid vapour downstream of thecartridge 14 in the mouthpiece cavity 20.

FIG. 7 shows the downstream end 30 of the blocking element 26. Theblocking element 26 comprises an aperture 96 for receiving the journalportion 86 of the shaft 84 on the cartridge housing 32. The shaft 84 hasbeen omitted from FIG. 7 to show the aperture 96. During assembly of thecartridge assembly 10, the aperture 96 is elastically deformed toaccommodate the retaining portion 88 of the shaft 84 as the retainingportion 88 is pushed through the aperture 96. Once the retaining portion88 has been pushed fully through the aperture 96, the step change indiameter between the retaining portion 88 and the journal portion 86prevents the retaining portion 88 being pulled back through the aperture96. The diameter of the journal portion 86 is slightly smaller than thediameter of the aperture 96 so that the journal portion 86 may rotatefreely within the aperture 96, which allows rotation of the cartridge 14with respect to the blocking element 26. When the journal portion 86 ispositioned within the aperture 96, the downstream end wall 82 of thecartridge housing 32 abuts the upstream end of the blocking element 26.

The blocking element 26 further comprises a first airflow aperture 98and a diametrically opposed second airflow aperture 100, each airflowaperture having a quarter-circular shape. A first blocking portion 102extends between a first end of the first airflow aperture 98 and asecond end of the second airflow aperture 100. A second blocking portion104 extends between a second end of the first airflow aperture 98 and afirst end of the second airflow aperture 100.

The first airflow aperture 98 also forms a guide opening in which theguiding pin 90 of the cartridge body 32 is received. The blockingelement 26 comprises a first recess 106 at the first end of the firstairflow aperture 98 for receiving the guiding pin 90 when the cartridge14 is in a first position with respect to the blocking element 26. Theblocking element 26 comprises a second recess 108 at the second end ofthe first airflow aperture 98 for receiving the guiding pin 90 when thecartridge 14 is in a second position with respect to the blockingelement 26.

When the cartridge 14 is in the first position, the first blockingportion 102 obstructs the first air outlet 92 on the cartridge body 32and the second blocking portion 104 obstructs the second air outlet 94on the cartridge body 32. A first detent 110 on the blocking element 26increases the force required to move the guiding pin 90 out of the firstrecess 106, which reduces the risk of the cartridge 14 beingaccidentally rotated out of the first position.

When the cartridge 14 is in the second position, the first air outlet 92on the cartridge body 32 is in fluid communication with the mouthpiececavity 20 via the first airflow aperture 98 and the second air outlet 94on the cartridge body 32 is in fluid communication with the mouthpiececavity 20 via the second airflow aperture 100. A second detent 112 onthe blocking element 26 increases the force required to move the guidingpin 90 into the second recess 108, which provides a user with a tactileconfirmation when the cartridge 14 has been fully rotated into thesecond position. The second detent 112 also retains the guiding pin 90in the second recess 108 to retain the cartridge 14 in the secondposition during use of the cartridge assembly 10.

During use of the cartridge assembly 10, a user removes the removableseal 36 from the upstream end of the cartridge 14 and rotates thecartridge 14 into the second position so that the first and second airoutlets 92, 94 are in fluid communication with the mouthpiece cavity 20.The cartridge assembly 10 is combined with an aerosol-generating deviceto form an aerosol-generating system, the cartridge assembly 10receiving a heater of the aerosol-generating device into the thirdcompartment 48 to heat the first and second compartments 44, 46. When auser draws on the downstream end 16 of the mouthpiece housing 12, air isdrawing into the cartridge assembly 10 through the first and second airinlets 62, 64. Air flows from the first and second air inlets 62, 64through the first and second compartments 44, 46 where nicotine vapourand acid vapour are entrained in the airflow. The nicotine and acidvapours flow through the first and second air outlets 92, 94 into themouthpiece cavity 20 via the first and second airflow apertures 98, 100of the blocking element 26. In the mouthpiece cavity 20 the nicotine andacid vapours react in the gas phase to form an aerosol of nicotine saltparticles which is delivered to the user through the mouthpiece housingair outlet 22.

1.-21. (canceled)
 22. A cartridge assembly for an aerosol-generatingsystem, the cartridge assembly comprising: a mouthpiece housing havingan upstream end and a downstream end, the mouthpiece housing defining amouthpiece cavity extending between the upstream end of the mouthpiecehousing and the downstream end of the mouthpiece housing; a blockingelement secured within the mouthpiece cavity and comprising an upstreamend and a downstream end; and a cartridge positioned at the upstream endof the mouthpiece housing, the cartridge comprising: an upstream end anda downstream end, a first compartment having a first air inlet at theupstream end of the cartridge and a first air outlet at the downstreamend of the cartridge, and a second compartment having a second air inletat the upstream end of the cartridge and a second air outlet at thedownstream end of the cartridge, wherein the downstream end of thecartridge abuts the upstream end of the blocking element, wherein thecartridge is rotatable with respect to the blocking element from a firstposition to a second position, and wherein the blocking element isshaped so that the upstream end of the blocking element obstructs thefirst air outlet and the second air outlet when the cartridge is in thefirst position, and the first air outlet and the second air outlet areboth in fluid communication with the mouthpiece cavity when thecartridge is in the second position.
 23. The cartridge assemblyaccording to claim 22, wherein one of the blocking element and thecartridge comprises an aperture, wherein the other of the blockingelement and the cartridge comprises a shaft, and wherein at least aportion of the shaft is positioned within the aperture.
 24. Thecartridge assembly according to claim 23, wherein the aperture extendsthrough the blocking element between the upstream end of the blockingelement and the downstream end of the blocking element, and wherein theshaft extends from the downstream end of the cartridge.
 25. Thecartridge assembly according to claim 23, wherein the shaft comprises ajournal portion positioned within the aperture and a retaining portionat an end of the journal portion, and wherein the retaining portion ispositioned outside of the aperture and has a diameter that is largerthan a diameter of the aperture.
 26. The cartridge assembly according toclaim 22, wherein the cartridge comprises a guiding pin extending fromthe downstream end of the cartridge, wherein the guiding pin abuts afirst portion of the blocking element when the cartridge is in the firstposition, and wherein the guiding pin abuts a second portion of theblocking element when the cartridge is in the second position.
 27. Thecartridge assembly according to claim 22, wherein the cartridge furthercomprises: a cartridge housing positioned at the upstream end of themouthpiece housing and rotatable with respect to the blocking elementfrom the first position to the second position; and a cartridge bodysecured within the cartridge housing, the cartridge body defining thefirst compartment and the second compartment.
 28. The cartridge assemblyaccording to claim 22, wherein the blocking element is spaced apart fromthe downstream end of the mouthpiece housing, and wherein a portion ofthe mouthpiece cavity between the downstream end of the blocking elementand the downstream end of the mouthpiece housing forms a mixing chamber.29. The cartridge assembly according to claim 28, wherein the mouthpiecehousing comprises a ventilation air inlet positioned between theblocking element and the downstream end of the mouthpiece housing, theventilation air inlet extending through the mouthpiece housing andproviding fluid communication between an exterior of the mouthpiecehousing and the mixing chamber.
 30. The cartridge assembly according toclaim 22, wherein the blocking element comprises a first airflowaperture configured to overlie the first air outlet when the cartridgeis in the second position and a second airflow aperture configured tooverlie the second air outlet when the cartridge is in the secondposition.
 31. The cartridge assembly according to claim 30, wherein theblocking element has a circular shape, and wherein the first airflowaperture and the second airflow aperture each have an arcuate shape. 32.The cartridge assembly according to claim 31, wherein the first airflowaperture and the second airflow aperture are diametrically opposed. 33.The cartridge according to claim 31, wherein the first airflow apertureand the second airflow aperture each extend along a quarter-circular arclength.
 34. The cartridge according to claim 30, wherein the blockingelement comprises a first blocking portion positioned between a firstend of the first airflow aperture and a second end of the second airflowaperture, wherein the blocking element comprises a second blockingportion positioned between a second end of the first airflow apertureand a first end of the second airflow aperture, wherein the firstblocking portion is configured to obstruct the first air outlet when thecartridge is in the first position, and wherein the second blockingportion is configured to obstruct the second air outlet when thecartridge is in the first position.
 35. The cartridge assembly accordingto claim 22, wherein the mouthpiece housing comprises a downstream wallportion extending across the downstream end of the mouthpiece cavity,the mouthpiece housing comprising a mouthpiece housing air outletextending through the downstream wall portion.
 36. The cartridgeassembly according to claim 22, further comprising a seal extendingacross the upstream end of the cartridge.
 37. The cartridge assemblyaccording to claim 22, further comprising a nicotine source positionedwithin the first compartment and an acid source positioned within thesecond compartment.
 38. The cartridge assembly according to claim 22,wherein the cartridge further comprises a third compartment configuredto receive a heating element of an aerosol-generating device, whereinthe third compartment comprises a compartment opening at the upstreamend of the cartridge, and wherein the third compartment is positionedbetween the first compartment and the second compartment.
 39. Thecartridge assembly according to claim 22, wherein the cartridge furthercomprises a susceptor positioned between the first compartment and thesecond compartment.
 40. An aerosol-generating system, comprising: acartridge assembly according to claim 22; and an aerosol-generatingdevice comprising a device cavity configured to receive an upstream endof the cartridge assembly and a heater configured to heat the firstcompartment and the second compartment of the cartridge of the cartridgeassembly.
 41. The aerosol-generating system according to claim 40,wherein the heater comprises a heating element positioned within thedevice cavity, wherein the cartridge further comprises a thirdcompartment configured to receive the heating element, wherein the thirdcompartment comprises a compartment opening at the upstream end of thecartridge, and wherein the third compartment is positioned between thefirst compartment and the second compartment.
 42. The aerosol-generatingsystem according to claim 40, wherein the heater comprises an inductiveheater surrounding at least a portion of the device cavity, and whereinthe cartridge comprises a susceptor positioned between the firstcompartment and the second compartment.